• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.17 no.2
• /
• pp.103-108
• /
• 2018

In interrupted cutting, the workpiece has a groove that impacts both the cutting tool and the workpiece. Therefore, cutting tool damage occurs rapidly. In this study, I performed interrupted cutting of carbon steel for machine structures (SM20C) using an uncoated carbide tool (SNMG120404, P20), and observed tool damage, cutting chip shape, and the workpiece surface. Results: Under the specific cutting conditions of feed rate = 0.066 mm/rev, cutting speed = 120 m/min, and depth of cut = 0.1 mm; and feed rate = 0.105 mm/rev, cutting speed = 120 m/min, and depth of cut = 0.2 mm, the observed tool damage was small. Similar chip shape was observed (Expt. No. 1, 3, 7). Workpiece damage was observed (Expt. No. 3, 5, 7, 9).

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 1997.04a
• /
• pp.1038-1043
• /
• 1997

To adapt the neural network proess for the purpose of determination of optimal utting onditions (optimal cutting speed and feed rate), some selection strategies for the machining factors are necessary, which is considered planning cutting process. In this case, factors that have both nonlinearity and strong relationship must be selected. Although tool grade and chemical properties of workpiece material have strong effect to cutting speed, it's not easy to find a analytic relation between them. In this paper, a mathematical method for determining the optimal amount of cutting (depth of cut, feed rate) is presented by tool goemetry and heat generation during cutting process. And various tool grade and workpiece material groups ase classified based on its chemical properties. Thier chemical composition and hardness are used as input pattern for neural network learnig. The result of learning shows the relationship between tool grade and workpiece material and it is proved that it can be used as a sub-system for automatic process planning system.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.10a
• /
• pp.354-361
• /
• 2005

In high speed cutting process, due to the friction between the tool and workpiece, a temperature rise of contacting part is serious. It need to develop cutting tool for overcoming such a poor condition. So now, some studies, the optimization of tool shapes, the fine grains of tool material, multi-layer coating of tools are processing. If mirror finishing on the tool is processed, there is advantage of relation between chip and tool, because of less friction, and also tool's lift would be increased. As a result mirror like finishing is expected efficient enhancement of tool. Generally, it is too difficult to process by a general way for tools of complex shapes, it is required a new method to process such complex shape tools. The magnetic fluid polishing technique can polish the workpiece of complex shape, because the polishing method which polishes as compress the workpiece by the magnetism abrasives to arrange to the linear according to the line of magnetic force. In this paper, We polished the surface of the high speed cutting tool using the magnetic fluid polishing technique, to enhance the performance of the high speed cutting tool.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2000.06a
• /
• pp.19-27
• /
• 2000

High speed machining (HSM), specifically end milling and ball end cutting, is attracting interest in the die/mold or aerospace industries for the machining of complex 3D surfaces. HSM of difficult-to-cut materials such as die/mold steels, titanium alloys or nickel based superalloys generates the concentrated thermal/frictional damage at the cutting edge of the tool and rapidly decreases the tool life. Following a brief introduction on HSM and reated aerospace or die/mold work, the paper reviews published data on the effect of cutter/workpiece orientation and cutting environments on tool performance. First, experimental work is detailed on the effect of cutter orientation on tool life, cutting forces, chip formation, specific force and workpiece surface roughness. Cutting was performed using 8 mm diameter PVD coated solid carbide cutters with the workpiece mounted at an angle of 45 degree from the cutter axis. A horizontal downwards cutting orientation proveded the best tool life with cut lengths ∼50% longer than for all other directions (horizontal upwards, vertical downwards, vertical upwards). Second, the cutting environments were investigated for dry, flood coolant, and compressed chilly air coolant cutting. The experiments were performed for various hardened materials and various coated tools. The results show that the cutting environment using compressed cilly air coolant provided better tool life than the flood coolant or the dry.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.10 no.4
• /
• pp.57-63
• /
• 2011

The aim of this study is to analyze turning process using commercial FEM simulation code. Various simulation models of orthogonal cutting process for 3 layers of metallic material have been simulated and analyzed. The workpiece material used for the orthogonal plane-strain metal cutting simulation consists of three layers, which are Allow Tool Steel, Aluminum and Stainless Steel. The finite element model is composed of a deformable workpiece and a rigid tool. The tool penetrates through the workpiece at a constant speed and constant feed rate. As an analytical result, detailed cutting temperature, strain, pressure, residual stress for both a tool and each layer of workpiece were obtained during the turning process. It has been closely observed that the chip flow curve deforms continuously.

• Journal of the Korean Society for Precision Engineering
• /
• v.15 no.6
• /
• pp.79-89
• /
• 1998

In determining optimal cutting condition for face milling operation, tool wear is an important factor. For the purpose of establishing the relationship between various machining factors and tool wear, cutting tests have been performed. As a result, hardness and chemical composition of workpiece material, chemical composition and grain size of cutting tool and cutting speed have been selected as machining factors. In addition, relationship between feed rate and workpiece hardness has been observed. Prior to utilizing cutting conditions recommended by ‘Machining Data Handbook(MDH)’ as a knowledge base, an analysis for the validity of the MDH has been provided. Based on this analysis, tool life criteria applied by MDH has been modified. Finally, using MDH recommended data for neural network trainning, the results from the trained neural network for optimal cutting condition for some given workpiece and cutting tool can be used as reference cutting conditions.

• Journal of the Korean Society of Manufacturing Process Engineers
• /
• v.10 no.6
• /
• pp.9-15
• /
• 2011

Any relative deformation between the cutting tool and the workpiece at machining point results directly in geometric and dimensional errors. The sources of relative deformations between the cutting tool and the workpiece at the contact point may be due to vibration, thermal deformation and cutting forces. In this paper, geometric error prediction of workpiece in turning has been investigated. To reach this goal, turning experiments are carried out according to selected cutting conditions. The variable cutting conditions are cutting speed, depth of cut and feed rate. The results will be useful as a guidance to select cutting conditions to improve the geometrical accuracy.

• Transactions of the Korean Society of Machine Tool Engineers
• /
• v.17 no.5
• /
• pp.123-130
• /
• 2008

In order to clarify detailed mechanism of the flexible disk grinding system, workpiece length was introduced and its performance was evaluated. Flat zone ratio increased as the workpiece length increased. Increasing wheel speed and depth of cut also enhanced process performance by producing larger flat zone ratio. Neural network system was successfully applied to predict minimum depth of engagement and flat zone ratio. An additional input parameter as workpiece length to the neural network system enhanced the prediction performance by reducing error rate. By rearranging the Input combinations to the network, the workpiece length was precisely predicted with the prediction error rate lower than 2.8% depending on the network structure.

• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.8
• /
• pp.21-28
• /
• 1997

This paper presents the influence of the process parameters on the change in dynamic behavior of a lathe turning system. With variation of feed rate, depth of cut, direction of tool motion, cutting speed and tool location along the workpiece, the dynamic characteristics of stable cutting, chatter transition and fully developed chatter regions are demonstrated. The workpiece vibration during machining is continuously measured at different tool locations along the workpiece and quantitatively analyzed. Complex linear behavior due to change of process parameter values as well as fundamental wystem nonlinearity due to change of process configuration indicated by a tool path dependence of the locations of chatter onset and disappearance are described. Finally, the structural characteristics of the turning system which can have large and nonlinear effects on system behavior are presented.

• Proceedings of the Korean Society of Machine Tool Engineers Conference
• /
• 2002.04a
• /
• pp.251-254
• /
• 2002

The technique of high speed machining is widely studied in machining field. In this study, TiAIN single-layered and TiAIN/TiN double-layered coatings were applied to end-mill by an arc ion plating technique. Their performances were comparatively studied about cutting force, tool wear, tool life and surface roughness of workpiece under high speed cutting conditions. The TiAIN single-layer coated tool showed higher wear-resistance due to its higher hardness, while the TiAIN/TiN double-layer coated tool showed better performance for high metal removal, i.e., high fled per tooth condition due to its higher toughness. The surface roughness of the workpiece was not influenced by the wear amount of coated tools.